Apparatus for making wallboards



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Oct. 7, 1947. w. s. BRUBACHER 2,428,512

APPARATUS FOR MAKING WALLBOARDS Filed May 10, 1944 2 Sheets-Sheet 1 u \lqubm HUG? Oct. 7, 1947. w. s. BRUBACHER 2,423512 APPARATUS FOR HAKING WALLBOARDS Filed Kay 10, 1944 2 Sheets-Sheet 2 5.2 I a/ l I NV EN TOR W/Lz mm Gfflzuancwaz F E xxx,

A RNEYS Patented Oct. 7, 1947 tea-ital duo APPARATUS FOR MAKING WALLBOARDS William G. Brubacher, Montreal, Quebec, Canada Application May 10, 1944, Serial No. 534,865 In Canada May 29, 1943 13 Claims.

This invention relates to an apparatus for making cavitated wall board, and more specifically to an apparatus for making such wall board from organic fibrous materials such as those produced from ood, s raw. sugar cane, etc.

In mv copending ap lication Serial No. 430,422, filed February 11, 1942, now Patent No. 2,370,393, granted February 27, 1945, I have disclosed an appara us of the continuous type for manufacturing cavitated wa l boards from fibrous materials of the organic type referred to, Such a paratus is particu arlv a apted for the quantity production of cavitated board in factories of substant a s ze.

An important ob ect of the present invention is to provide a rela ively small a aratus for manu acturin individual cavi ated boards and whi h is a apted for use in relatively small manufac ur n plants.

A further ob ec+- s to rovi e such an ap ara*us which is adao d o rec e a charge of the ini ia m t ial and o e oui kly and ea ily operated to p odu a i g e cavi a ed board.

A f rth r obiect is to pr vide uc an ap ara us w i h i compact in si"'e and ea y to install a o er o d ce ca itated boards in relatively sma l quanti ies.

A fur her object is to provi e such an ap aratus whi h is particuarly efficient for the manufac ure of wall boards from fibrous materials of the charac r referred to. and wherein he boards w ll be uniform, of low den ity and substant al thickn s to rovide a mavimum insulating value, and f relatively light weight. etc.

O her ob ects and advantages of the inventi n will be ome a parent during the course of the fo lowing description.

In t e drawings I have shown one embodiment of t e invention. In this showing F gure 1 is a ce tral vertical sectional view through the apparatus, parts being shown in elevation.

Figure 2 is an en arged horizontal sectional view on line 22 of Figure 1,

Fi ure 3 is an enlarged fragmentary vertical sectional view on line 3--3 of Figure 1,

Figure 4 is an enlarged detail sectional view through the tube holder looking in the same direction as in Figure 3, parts being shown in elevation,

Figure 5 is a detail sectional view on line 5--5 of Figure 4, and,

Figure 6 is a similar view on line 65 of Figure 4.

Referring to Figure 1 the numeral l0 designates a vertical casin or vat closed at its lower end by a head I I. As will become apparent later, the upper and lower ends of the vat 10 form chambers 12 and 13 for a purpose to be described. Intermediate its ends the vat II) has its walls perforated as at l 4 for the flow of liquid into a drainage chamber l5. This chamber is formed at opposite sides of the vat by walls l6 welded or otherw se secured to the walls of the vat l0. At the other sides of the vat, the chamber I5 is defined by doors to be referred to later, Each of the walls H5 at the bottom thereof defines a guide for a purpose to be described.

Referring to Figures 2 and 3 the numeral 20 de i nates ea h of a pair of doors shaped in crosssec ion ge eraly similar to the walls I 6 and co- O eIating erewith to form continuatons of the drainage chamber I5. Each of the doors 2!! is adapted to be opened or removed for the introdu tion in o a d the r moval from the vat Ill of a form g device n icat d as a whole by the num ral 2| and referred to in detail later. Any suit ble means may be employed for providing for the openin or removal of the doo s 20, F r examp e. each door 20 may be provided at its upp r e d w th a flange 22 normal y arranged beneath a keeper 23 welded or otherwise secured to the vat Ill. The bottom of each door 20 may be p ovided with a similar flange 24 ar anged ben ah a k eper 25 slotted as at 26 for the reception of a bolt 21 carrying a thumb nut 28. It wi l be apparent that the nuts 28 may be loosened to permit the keepers 25 to slide downwardly free of the flanges 24 of both doors, whereby the lower ed e of each door may be swung outwardly a short distance and then pulled downwardly to be removed from the vat.

The forming dev ce 2| comprises a generally rectan ular frame 30 s l t as at 3| (Figure 2) to form angular complementary sections 32. Any suitable preferably quick releasable means is em loyed for clamping the two frame mem-\ bers 32 in their normal positions shown in Figure 2. Such a quick detachable device is indicated as a whole by the numeral 33 and since such device is conventional, it need not be referred to in detail.

Opposite sides of the frame 30 are apertured as at 35 (Figure 4) in alined relation to receive forming tubes each of which is indicated as a whole by the numeral 31 and comprises complementary tube sections 38 and 39 the adjacent edges of which are sloped as at 40 whereby each tube section is relatively wedge shaped. When th r spective ends of the tube sections are flush as shown in Figure 4 the tube will be in circular form as shown in Figures 5 and 6. The tube section 38 is provided with a central web 4i receivable between spaced webs 42 carried by the tube section 39. The engagement of these web elements prevents lateral movement of the tube sections with respect to each other as will be apparent. The web elements have their free edges sloped in planes parallel to the slope of the junction 48 of the tube elements 38 and 39 as shown in Figure 4. The webs 42 are apertured adjacent one end as at 43, while each of the webs 4| is similarly apertured adjacent the opposite end of the tube as at 44, these apertures being provided for engagement with pulling elements to pull the tube sections out of the frame 30 after a board has been formed in a manner to be described.

During the formation of each board, the forming device is arranged within the vat between the chambers l2 and I3. The frame 30 is preferably identical in shape and size to the crosssectional shape and size of the vat I0, the upper and lower ends of the vat being fixed with relation to each other by the walls l6 welded thereto and by any other suitable bracing means if desired.

An upper plunger 48 is vertically reciprocable in the chamber l2. This plunger is carried by a piston rod 49 having a piston 58 at its upper end reciprocable in a hydraulic or other fluid pressure cylinder 5|. A four-way valve 52 is provided with branch pipes 53 and 54 leading to the respective ends of the cylinder 5| and is supplied with pressure fluid from a suitable source through a pipe 55. The valve 52 has a conventional exhaust port (not shown) for exhausting either end of the cylinder 5| when the other end is connected to the pressure source. Upward movement of the plunger 48 is limited by stops 58 engageable with a flange 51 secured to the upper end of the vat Hi. The plunger is provided with upwardly extending rods 58 carrying stops 59 adjustable as to position by suitable nuts 60 and engageable with the flange 51 to limit downward movement of the plunger 48 according to the desired thickness of th wall board to be made, as will become apparent. The plunger 48 is faced with a lower wire mesh screen 6| The vat I0 is provided with a lower plunger 65 as shown in Figure 1, and both of the plungers 48 and 85 are perforated for a purpose to be described. The top face of the plunger 65 is provided with a fairly rigid wire mesh or other perforated sheet 66 and a finer mesh screen 61 overlies the element 66. The plunger 65 is carried by the upper end of a piston rod 68 extending through the head H and provided at its lower end with a piston 69 reciprocable in a cylinder 10. Pressures in the ends of the cylinder 19 are controlled by a four-way valve ll similar in characteristics to the valve 52, through branch pipes 12 and "3 connected to the respective ends of the cylinder 10. Pressure fluid is supplied to the valve H through a pipe 14.

Downward movement of the plunger 65 is limited by suitable stops [8 carried by the head II. The plunger 65 carries a plurality of depending rods 19 each of which carries a stop member 80 adjustable on the rod by a nut 8|. The nuts 8| are adjusted in accordance with the desired thickness of the wall board to be made, as will become apparent.

The vat I8 is provided near the upper end of the chamber I2 with inlets 85 for the fiber stool;

solution. This solution is relatively thin and may carry, for example, from .5% to 2% solids. Water from the solids flows by gravity through the perforations l4 into the drainage chamber l5 and from such chamber the liquid flows through outlet pipes 86 controlled by valves 81. Water will also flow through the elements 66 and 67 and through the perforations in the plunger 65, and such fluid is withdrawn from the bottom of the vat I0 through suitable pipes 88 provided with valves 89 and may be connected to a suitable source of suction. The valves 81 are closed while the vat is being charged with fibre stock, and are opened during the pressure operation, as will be referred to below.

Each board is formed within the forming device 2|. A plurality of such devices are employed and after one board is formed the frame 2| is removed from the apparatus and another device introduced thereinto. To facilitate introduction of the devices 2| into the vat I0 and their removal therefrom, supporting rails 90 and 9| may be arranged adjacent the respective sides of the apparatus. Assuming that th rails 90 are at the inlet side of the apparatus, a pusher 92 may be arranged over such rails and connected to a rod 93 which may be either manually or power operated.

The operation of the apparatus is as follows:

With the parts in the positions shown in Figure 1 a charge of material is introduced into the vat I!) through the inlets 85 while all of the drain valves are closed. When the predetermined amount of fibre stock has been run into the vat, the valves 81 and 89 are opened, whereupon the valves 52 and H are operated either simultaneously or successively to introduce pressure into the remote ends of the cylinders 5| and 18 to move the piston 50 downwardly and to move the piston 89 upwardly. The two plungers 48 and 65 thus approach each other. During such operation, liquid will flow by gravity through the openings l4 to be discharged through the drainage chamber l5 and pipes 86. Liquid also will flow through the perforated plunger 65 into the bottom of the vat ID to be discharged through the pipes 88. As the plungers approach each other, therefore, the charge of material progressively becomes denser. The plungers are so shaped as to be adapted to enter the top and bottom of the forming device 2| within the frame 30 and when the plungers reach their limits of movement as indicated approximately by the dotted lines in Figure 1, little liquid will remain in the body of the fiber in the forming device 2|. It will be apparent that pressure will be exerted against the fibrous material to express liquid therefrom, some of such liquid passing downwardly through the plunger 65 while some of it will be forced upwardly through the perforated plunger 48 to be discharged through the openings M. The stops 59 and will be positioned to arrest movement of the plungers at the proper point according to the desired thickness of the board. This board will be defined by the woven wire members BI and 61 and by the frame 30 and the tubes 31 will be embedded in the board.

Pressure will be maintained on the board element thus formed until all of the excess water has drained from the apparatus. The valve 52 will then be operated to move the plunger 48 upwardly to the position shown in Figure l. The newly formed board is now ready to be removed, as described below, and since the element 61 will have merely laid loosely on the plunger 65 it will adhere to the board and will be removed therewith. The element 51 will determine the nature of the surface of the finished board and will adhere thereto within the bottom limit of the frame 30.

After the plunger 48 has been moved to the position shown in Figure 1, the nuts 28 (Figure 3) of both doors 20 will be loosened to drop the keepers 25, whereupon the respective doors 20 will be swung outwardly to a slight extent at their lower edges and then withdrawn downwardly. The pusher 92 is then operated to move the device 2| through the discharge door opening onto the rails 9|. The pusher is then retracted and a new device 2| and tray 61 placed in position on the rails 90 and moved by the pusher into the apparatus. If desired, an empty frame 2| and tray 61 may be placed between the pusher 92 and the filled frame 2| within the apparatus, whereupon the pusher may be operated to move the empty frame into the apparatus and discharge the filled frame therefrom. The empty frame will move to the position shown in Figure 3 and the filled frame may be pulled by hand from the apparatus. The plunger 65 remains in operative position to support the newly formed board, and after the removal of such board, the valve H is operated to effect movement of the plunger 65 downwardly to its inoperative position shown in Figure 1. With an empty frame and its tray 61 in position in the apparatus, the doors 20 are then closed and the operation repeated to form a new board while the previously formed board is removed from its device 2|.

The filled device 2| is placed upon a suitable table or the like whereupon hooks are inserted into the opposite ends of each tube 31 and engaged in the openings 43 and 44. The tube section 38 is pulled toward the left as viewed in Figure 4 while the tube section 39 is pulled toward the right. After the initial pulling of one of the tube sections the sloping surface 40 will provide for the contraction of the tube whereupon both sections thereof may be easily removed. The locking devices 33 (Figure 2) are then released whereupon the frame sections 32 may be easily removed from the formed board. The board, which is still supported by the sheet or tray 67, is then transferred to a suitable drying kiln, before or after which the screen 61 adhering to the board may be peeled therefrom.

From the foregoing it will be apparent that the present apparatus is simple and compact in construction and capable of relatively economical manufacture so as to render its use practicable in small plants to supply local trade with cavitated fiber boards. The boards are relatively light and possess greater structural strength for the quantity of material therein than would be true without the cavitations left in the boards after the tubes 31 are removed therefrom. Such openings provide for a thicker board which also possesses high insulating value, and the making of the board under the pressure of the plungers provides a board of relatively great structural strength which is comparatively moisture proof and less subject to warping, expansion and contraction. The apparatus is easy to operate and the boards may be relatively rapidly made in successive operations of the apparatus.

Boards of different thicknesses readily may be made by employing forming devices 2| with tubes 31 of different sizes, and by suitably adjusting the stops 59 and 80. Thus while a single apparatus makes all boards of the same length and 6 width, boards of any desired thickness may be made with equal facility.

It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same and that various changes in the shape, size and arrangement of parts may be resorted to without departing from the spirit of the invention or the scope of the subjoined claims.

I claim:

1. An apparatus for making fiber boards from a thin watery mix containing organic fibers, comprising a vertical vat, plungers vertically reciprocable in said vat and having horizontal forming faces, means for introducing the mix into said vat between said plungers when the latter are moved away from each other, and means for draining water from said vat as said plungers are moved toward each other to substantially reduce the water content of the mix and result in the formation of a board between the forming faces of said plungers, said draining means comprising a chamber surrounding said vat and the latter having openings therearound affording communication between the interior of said vat and said chamber.

2. An apparatus for making fiber boards from a thin watery mix containing organic fibers, comprising a vertical vat, plungers reciprocable in said vat, means for introducing the mix into said vat between said plungers when the latter are moved away from each other, a forming device extending transversely of said vat inter-' mediate the ends thereof, means for draining liquid from the mix introduced into said vat, and means for moving said plungers toward each other to a position in proximity to said forming device to produce a solid board between said plungers when the liquid content of the mix has been reduced to a predetermined extent, said draining means comprising a chamber surrounding said vat and the latter having perforations therearound above and in proximity to said forming device and communicating with said chamher.

3. An apparatus for making fiber boards from a thin watery mix containing organic fibers, comprising a vertical vat, plungers reciprocable in said vat, means for introducing the mix into said vat between said plungers when the latter are moved away from each other, a forming device extending transversely of said vat intermediate the ends thereof, said device including a plurality of spaced forming elements, means for draining liquid from the mix in said vat, and means for moving said plungers toward each other to positions in spaced relation to said spaced elements to form a resultant board between said plungers when the liquid content of the mix is reduced to a predetermined extent, with said spaced elements embedded in the board, said draining means comprising a chamber surrounding said vat and the latter having perforations therearound above and in proximity to said forming device and communicating with said chamher.

4. Apparatus constructed in accordance with claim 3 wherein said forming device comprises a frame removably carrying said spaced elements whereby removal of said elements will leave the resultant board with cavitations therein, said chamber having a wall removable to provide for the removal of said forming device from said vat.

5. Apparatus constructed in accordance with claim 3 wherein said forming device comprises a frame formed of complementary sections, and means for clamping said sections together, said frame comprising opposite portions apertured to slidably support said spaced elements whereby the resultant board is left with cavitations therein upon the removal of said spaced elements.

6. An apparatus for making fiber boards from a thin watery mix containing organic fibers, comprising a vertical vat, plungers reciprocable in said vat, means for introducing the mix into said vat between said plungers when the latter are moved away from each other, a drainage chamber arranged outwardly of said vat intermediate the ends thereof, said vat having apertures therearound for the flow into said chamber of liquid from the mix in said vat, and means for moving said plungers toward each other to form the fibrous material therebetween into a board when liquid in the mix has drained therefrom to a predetermined extent.

7. An apparatus for making fiber boards from a thin watery mix containing organic fibers, comprising a vertical vat, plungers reciprocable in said vat, means for introducing the mix into said vat between said plungers when the latter are moved away from each other, a forming device comprising a frame corresponding in shape and size to the cross-sectional shape and size of said vat, a. door carried by said vat and adapted to be opened for the introduction of said forming device into said vat transversely thereof, said vat being provided with guideways for guiding and supporting said forming device in said vat, said forming device having relatively straight spaced forming element extending thereacross, means for moving said plungers toward each other to positions spaced from said forming elements to form a resultant board between said plungers with said forming elements embedded therein, and means intermediate the ends of and extending around said vat for draining liquid therefrom.

8. An apparatus for making fiber boards from a, thin watery mix containing organic fibers, comprising a vertical vat, plungers reciprocable in said vat, means for introducing the mix into said vat between said plungers when the latter are moved away from each other, a forming device comprising a frame corresponding in shape and size to the cross-sectional shape and size of said vat, a door carried by said vat and adapted to be opened for the introduction of said forming device into said vat transversely thereof, said vat being provided with guideways for guiding and supporting said forming device in said vat, said forming device having relatively straight spaced forming elements extending thereacross, a drainage chamber arranged outwardly of said vat, said vat being provided adjacent said forming device with apertures therearound for the drainage into said chamber of liquid from the mix in said vat, a d mea s f r moving id ungers toward each oth r to positions extending inwardly beyond the vertical limits of said forming device in spaced relation to said forming elements to form a resultant board having opposite faces defined by said p ungers and with said forming elements embedded in such board.

9. An apparatus for making fiber boards from a th n watery mix containing organic fibers, comprising a vertical vat, plungers reciprocable in said vat, means for introducing the mix into said vat between said plungers when the latter are moved away from each other, one wall of said vat being provided with a door, parallel guideways within said vat, a forming device insertable into said vat through said door to be slidably supported on said guideways, a drainage chamber arranged outwardly of said vat, said vat having apertures therearound just above said forming device for the drainage of liquid from the mix in the vat to said drainage chamber, and means for moving said plungers toward each other to positions in spaced relation adjacent said forming device to form a board therebetween, the upper plunger being apertured for the upward flow of liquid from between said plungers and thence outwardly into said drainage chamber through the apertures in said vat.

10. Apparatus constructed in accordance with claim 9 wherein said forming device comprises a frame having an inside size and shape corresponding to the size and shape of said lower plunger whereby the latter is adapted to enter the bottom of said forming device, and a finish-determining sheet resting on said lower plunger and adapted to adhere to the resultant board to be removed with such board and said forming device when the latter is withdrawn through said door.

11. Apparatus constructed in accordance with claim 9 wherein said forming device comprises a frame having an inside size and shape corresponding to the size and shape of said lower plunger whereby the latter is adapted to enter the bottom of said forming device, a finish-determining sheet resting on said lower plunger and adapted to adhere to the resultant board to be removed with such board and said forming device when the latter is withdrawn through said door, said lower plunger being apertured for the drainage of liquid downwardly therethrough, and a drain pipe connected to the bottom of said vat.

12. An apparatus for making fiber boards from a thin watery mix containing organic fibers, comprising a vertical vat, plungers reciprocable in said vat, means for introducing the mix into said vat between said plungers when the latter are moved away from each other, a drainage chamber arranged outwardly of said vat intermediate the ends thereof, said vat having apertures therearound for the flow into said chamber of liquid from the mix in said vat, the lower of said plungers being apertured for the flow of liquid therethrough, a drain pipe connected to the bottom of said vat, a forming device arranged in said vat transversely thereof adjacent said apertures, said forming device comprising spaced forming element extending transversely of said vat, and means for moving said plungers toward each other to positions in limited spaced relation to said forming elements to form a resultant board between said plungers with said forming elements embedded therein.

13. An apparatus for making fiber boards from a thin watery mix containing organic fibers, comprising a vertical vat, plungers reciprocable in said vat, means for introducing the mix into said vat between said plungers when the latter are moved away from each other, a forming device comprising a frame corresponding in shape and size to the cross-sectional shape and size of said vat, a door carried by said vat and adapted to be opened for the introduction of said forming device into said vat transversely thereof, said vat being provided with guideways for guiding and supporting said forming device in said vat. means for moving said plungers toward each searcn KW 10 other to form a, resultant board between said Number Name Date plungers, and means intermediate the ends of 1,872,533 Von Hildebrandt Aug. 16. 1932 and extending around said vat for draining liq- 1,995,145 Frost Mar. 19, 1935 uid therefrom. 1,273,527 Norris July 23, 1918 WILLIAM G. BRUBACHER. 5 937,781 Eddy Oct. 26, 1909 1,680,896 Marr Aug. 14, 1928 REFERENCES CITED 2,127,679 Dudley Aug. 23, 1938 753,038 Boschert Feb. 23, 1904 2; ggjgg gg g of m the 910,245 men m 19, 190,

10 UNITED STATES PATENTS FOREIGN PATENTS Number Name Date Number Country Date 1,861,849 Froblsher June 7, 1932 380,367 France Oct. 5, 1907 

